INSTALLATION INSTRUCTIONS - AEM Air Intake Systems

Equipped with AEM® Dryflow™ Filter No Oil Required!

INSTALLATION INSTRUCTIONS PART NUMBER: 21-573 2007-2012

AEM Induction Systems

TOYOTA

Yaris

L4-1.5L

1 (800) 992-3000

WWW: http://www.aemintakes.com

PARTS LIST Description

Qty.

Part Number

A

Air Filter Assy. 2.25 X 5" Dry Ele.

1

21-200DK

B

1/2' Bnd. Hose Clamp, 2.15-3.00"

1

9440

C

Zip Tie, 8" Tree Push-Mnt.

3

1-127

D

Bolt, Socket 8-32 X 5/16 SS

2

1-2023

E

Intake Pipe

1

2-719

F

Mount, Rubber 1" X 8mm

1

1228560

G

Washer, 8mm Soft Mount

1

559960

H

Nut, M8 Hex Serrated

1

444.460.08

I

Washer, M5 Split Lock SS

1

1-3046

J

Bolt, Hex M5-.8, 12mm

1

1-2098

K

Hose, Silicone 2.25x2"

1

5-222N

L

Hose Clamp, 2.25”

2

103-BLO-3620

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Read and understand these instructions BEFORE attempting to install this product. Failure to follow installation instructions and not using the provided hardware may damage the intake tube, throttle body and engine. ®

The AEM intake system is a performance product that can be used safely during mild weather conditions. During harsh and inclement weather conditions, you must return your vehicle to stock OEM airbox and intake tract configuration. Failure to follow these instructions will void your warranty. 1. Preparing Vehicle a. Make sure vehicle is parked on level surface. b. Set parking brake. c. If engine has run in the past two hours, let it cool down. d. Disconnect negative battery terminal. e. Do not discard stock components after removal of the factory system.

2. Removal of stock system

Unclip Remove a. Factory airbox system installed.

b. Unplug the Mass Air Flow (MAF) sensor wire connector. Loosen the two screws securing the MAF sensor and carefully remove the sensor. Unclip the EVAP VSV hose from the intake tube.

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Remove

Remove

c. Pull the EVAP VSV mounting clip free from the intake tube. Remove the Phillips head screw that secures the mounting bracket to the EVAP VSV.

d. Remove the crankcase ventilation hose from intake tube by squeezing the spring clamp to relieve tension.

Unclasp

e. Loosen the hose clamp and pull the intake tube clear of the throttle body.

f. Unclasp the two spring clips retaining the airbox lid.

Release

g. Lift the airbox lid and intake tube as an assembly. Release the wire harness clip from the underside of the airbox lid. Remove the airbox lid and intake tube from the engine bay. Remove the factory air filter element.

h. Remove the two lower airbox mounting bolts. Release the wire harness clip from the underside of the lower airbox. Remove the lower airbox from the engine bay.

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i. Remove the two bolts securing the airbox mounting bracket. Release the wire harness clip from the underside of the airbox mounting bracket. Remove the airbox mounting bracket from the engine bay. ®

3. Installation of AEM Intake System a. When installing the intake system, do not completely tighten the hose clamps or mounting hardware until instructed to do so.

b. Install the M8 rubber mount into the forward-most airbox bracket mounting hole.

c. Install the silicone coupler onto the throttle body. Loosely install the two 2.25” hose clamps.

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d. Install the MAF sensor into the AEM intake pipe. Secure with the two provided 832 socket bolts. Use care during the installation to avoid damaging the o-ring.

e. Install the AEM intake pipe into the engine bay. Align the mounting bracket onto the rubber mount installed in step 3b. Insert the other end of the intake pipe into the coupler installed on the throttle body.

f. Loosely secure the pipe’s mounting bracket to the rubber mount with the supplied M8 washer and nut.

g. Secure the EVAP VSV to the bracket on the intake pipe using the supplied M5 bolt and lock washer. Ensure the alignment tab aligns with the slot in the mounting bracket.

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h. Attach the crankcase breather hose to the intake pipe and secure in place with the factory spring clamp.

i. Raise the front of the vehicle with a jack. Refer to your owner’s manual for proper jack and jack stand placement to properly support vehicle. Support your vehicle using properly rated jack stands before wheel removal or while working under the vehicle. NEVER WORK UNDER A VEHICLE WITHOUT USING JACK STANDS. Remove the driver side wheel. Remove the five screws securing the lower splash guards.

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j. Remove the two plastic rivets by popping up the center with a small screwdriver. Pull the fender liner back to expose the inner bumper area.

k. Install the AEM air filter onto the end of the intake pipe. Slide it on until the shoulder inside the air filter is flush with the end of the pipe. Secure with the supplied 2.15-3.00" hose clamp.

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l. Plug in the MAF sensor connector to the MAF sensor.

m. If the wire harness behind the headlight rubs the intake pipe, secure it to the mounting tab with one of the supplied pushmount zip ties. Ensure the wire harness is NOT in tension. Depending on the length of the wiring harness, this step may not be necessary.

n. Route the MAF sensor connector wire harness under the intake pipe as shown. Secure the harness in two places using the remaining two push-mount zip ties.

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Factory airbox system installed

AEM intake system installed

4. Reassemble Vehicle a. Fender liner and splashguard: Install the fender liner, lower splash guard and any hardware that was removed in steps 3i through 3j. NOTE: Failure to install the fender liner will result in diminished performance and increase the potential for engine damage due to water ingestion in rainy conditions. b. Wheel: Install the driver side wheel using the factory torque specification (see owner’s manual). c. Position the inlet pipes for the best fitment. Be sure that the pipes or any other components do not contact any part of the vehicle. Tighten the rubber mount, all bolts, and hose clamps. d. Check for proper hood clearance. Re-adjust pipes if necessary and re-tighten them. e. Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are properly tightened. f. Reconnect negative battery terminals and start engine. Let the vehicle idle for 3 minutes. Perform a final inspection before driving the vehicle.

Install AEM® bypass valve Here

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If you choose to install an AEM bypass valve (sold separately) install it in the location ® specified. Refer to the AEM bypass valve installation instructions to ensure proper installation.

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5. Service and Maintenance a. AEM Induction Systems requires cleaning the intake system’s air filter element every 100,000 miles. When used in dusty or off-road environments, our filters will require cleaning more often. We recommend that you visually inspect your filter once every 25,000 miles to determine if the screen is still visible. When the screen is no longer visible some place on the filter element, it is time to clean it. To clean, purchase our Synthetic air filter cleaner, part number 99-0624 and follow the easy instructions. ® b. Use aluminum polish to clean your polished AEM intake tube. ® c. Use window cleaner to clean your powder coated AEM intake tube. (NOTE: DO NOT USE aluminum ® polish on powder coated AEM intake tubes).

For technical inquiries e-mail us at [email protected] or call us at 800.992.3000

AEM Air Intake System Warranty Policy ®

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AEM warrants that its intake systems will last for the life of your vehicle. AEM will not honor this warranty due to ® mechanical damage (i.e. improper installation or fitment), damage from misuse, accidents or flying debris. AEM will not warrant its powder coating if the finish has been cleaned with a hydrocarbon-based solvent. The powder coating should only be cleaned with a mild soap and water solution. Proof of purchase of both the vehicle and ® AEM intake system is required for redemption of a warranty claim. ®

This warranty is limited to the repair or replacement of the AEM part. In no event shall this warranty exceed the ® ® original purchase price of the AEM part nor shall AEM be responsible for special, incidental or consequential ® damages or cost incurred due to the failure of this product. Warranty claims to AEM must be transportation prepaid and accompanied with dated proof of purchase. This warranty applies only to the original purchaser of product and is nontransferable. Improper use or installation, use for racing, accident, abuse, unauthorized repairs ® or alterations voids this warranty. AEM disclaims any liability for consequential damages due to breach of any ® ® written or implied warranty on all products manufactured by AEM . Warranty returns will only be accepted by AEM when accompanied by a valid Return Merchandise Authorization (RMA) number. Credit for defective products will ® be issued pending inspection. Product must be received by AEM within 30 days of the date RMA is issued. If you have a warranty issue, please call (800) 992-3000 and our customer service department will assist you. A ® proof of purchase is required for all AEM warranty claims.

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10-7549E 03/13/14